Hinged ankle brace

ABSTRACT

An ankle brace includes a semi-rigid ankle cuff and a semi-rigid foot bed coupled to the semi-rigid ankle cuff. The semi-rigid ankle cuff includes a calf-supporting portion configured to extend around a lower calf of a wearer, and medial and lateral uprights extending generally downward from respective medial and lateral sides of the calf-supporting portion. The semi-rigid foot bed includes a foot plate including a posterior medial edge, a posterior lateral edge and is contoured to underlie at least a portion of a foot of the wearer. The semi-rigid foot bed includes medial and lateral wings extending generally upward from respective posterior medial and lateral edges of the foot plate, medial and lateral bend regions respectively joining the medial and lateral wings to the foot plate. Each of the medial bend region and the lateral bend region are more flexible than the foot plate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 15/179,806, filed Jun. 10, 2016, which is acontinuation of and claims priority to U.S. patent application Ser. No.13/851,725, filed Mar. 27, 2013 and now issued as U.S. Pat. No.9,364,366, which is a continuation application of and claims priority toU.S. patent application Ser. No. 11/243,754, filed on Oct. 4, 2005 andnow issued as U.S. Pat. No. 8,641,654, on Feb. 4, 2014, which claimspriority to U.S. Provisional Application Ser. No. 60/615,621, filed Oct.4, 2004, now expired. Each application is hereby incorporated byreference in their entireties.

BACKGROUND Field of the Disclosure

The present disclosure relates to orthopedic ankle braces.

Description of the Related Technology

A variety of ankle braces are currently available to prevent ankleinjuries, such as sprains. Some braces include purely soft components,and others incorporate rigid components. In general, these braces aredesigned to support the wearer's ankle and prevent unnatural movementsthat might cause injury.

SUMMARY

The preferred embodiments of the present ankle braces have severalfeatures, no single one of which is solely responsible for theirdesirable attributes. Without limiting the scope of these ankle bracesas expressed by the claims that follow, more prominent features will nowbe discussed briefly. After considering this discussion, andparticularly after reading the section entitled “Detailed Description,”one will understand how the features of the preferred embodimentsprovide advantages, which include support for high ankle sprains,improved inversion and eversion control, reduced foot slippage,calcaneus support, and incremental adjustability as well as enhancedcomfort, support and stability for a wearer.

In certain embodiments, the present ankle braces comprise a semi-rigidankle cuff, a semi rigid foot bed, a medial hinge, and a lateral hinge.The semi-rigid ankle cuff includes a calf-supporting portion configuredto extend around a posterior side of a lower calf of a wearer, a medialupright extending generally downward from a medial side of thecalf-supporting portion, and a lateral upright extending generallydownward from a lateral side of the calf-supporting portion. The footbed includes a foot plate contoured to underlie at least a portion of afoot of the wearer, a medial wing extending generally upward from themedial side of the foot bed, and a lateral wing extending generallyupward from the lateral side of the foot bed. The medial hinge rotatablyconnects the medial wing with the medial upright. The lateral hingerotatably connects the lateral wing with the lateral upright. The medialhinge is positioned higher than the lateral hinge relative to the footplate. Advantageously, this relative positioning of the medial hinge andthe lateral hinge closely simulates ankle anatomy, thus allowing anatural bending motion of a wearer's ankle.

In other embodiments, the present ankle brace comprises a semi-rigidankle cuff and a semi rigid foot bed. The semi-rigid ankle cuff includesa calf-supporting portion configured to extend around a posterior sideof a lower calf of a wearer, a medial upright extending generallydownward from a medial side the calf-supporting portion, and a lateralupright extending generally downward from a lateral side of thecalf-supporting portion. The semi rigid foot bed includes a foot platecontoured to underlie at least a portion of a foot of the wearer, a cutout portion configured to receive a heel of a wearer, a medial wingextending generally upward from a posterior medial edge of the footplate, and a lateral wing extending generally upward from a posteriorlateral edge of the foot plate. The foot bed is rotatably coupled to theankle cuff.

In other embodiments, the present ankle brace comprises a semi-rigidankle cuff and a semi-rigid foot bed rotatably coupled to the anklecuff. The semi-rigid cuff comprises a calf-supporting portion configuredto support a posterior side of an ankle of a wearer, and at least onesemi-rigid strap extending from the calf-supporting portion andincluding a ratchet mechanism to adjustably position the ankle cuff onthe ankle of a wearer.

In other embodiments, the present ankle brace comprises a semi-rigidshell configured to overlie and support at least a portion of a wearer'sankle and/or foot, and an outer sleeve configured to overlie at least aportion of the semi-rigid shell, and configured to apply compression tothe semi-rigid shell.

In other embodiments, the present ankle brace comprises a semi-rigidankle cuff configured to overlie and support at least a portion of acalf and/or ankle of the wearer, and a semi-rigid foot bed configured tounderlie at least a portion of the wearer's foot. The foot bed includesat least one of a medial posterior extension and a lateral posteriorextension. The at least one posterior extension is configured to cup andsupport a heel of the wearer.

In other embodiments, a method for applying an ankle brace is provided.The method comprises the steps of applying an inner liner to the ankleof the wearer, applying a semi-rigid shell including an ankle cuff andat least one strap to the inner liner, incrementally adjusting thecircumference of the ankle cuff, and securing the strap with respect tothe calf-supporting portion. The semi-rigid shell comprises a foot bedand an ankle cuff rotatably coupled to the foot bed, the ankle cuffcomprising a calf-supporting portion, at least one semi-rigid strapextending from the calf-supporting portion, and a ratchet mechanism toincrementally adjust a circumference of the ankle cuff.

In other embodiments, another method for applying an ankle brace isprovided. The method comprises the steps of applying a semi-rigid shellto the ankle, securing the semi-rigid shell about the ankle, applying anouter sleeve over the semi-rigid shell, and securing the outer sleevewith respect to the semi-rigid shell. The semi-rigid shell includesstructure that overlies and supports at least a portion of the ankle,and the outer sleeve is configured to overlie and compress at least aportion of the semi-rigid shell.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present ankle braces, illustratingtheir features, will now be discussed in detail. These embodimentsdepict the novel and non-obvious ankle braces shown in the accompanyingdrawings, which are for illustrative purposes only. These drawingsinclude the following figures, in which like numerals indicate likeparts:

FIG. 1 is a front perspective view of a preferred embodiment of thepresent hinged ankle brace;

FIG. 2 is a front perspective view of a semi-rigid shell of the hingedankle brace of FIG. 1, illustrating the semi-rigid straps of the shellin a disengaged configuration;

FIG. 3 is a partially exploded front perspective view of the hingedankle brace of FIG. 1, illustrating an inner liner of the brace removedfrom the semi-rigid shell;

FIG. 4 is a front elevational view of the semi-rigid shell of FIG. 2;

FIG. 5 is a left-side elevational view of the semi-rigid shell FIG. 2;

FIG. 6 is a right-side elevational view of the semi-rigid shell FIG. 2;

FIG. 7 is a detail front elevational view of the curved slot and ratchetmechanism of the semi-rigid straps of the ankle brace of FIG. 1;

FIG. 8 is a detail front elevational view of the curved slot and ratchetmechanism of FIG. 7 in a first rotated position;

FIG. 9 is a detail front elevational view of the curved slot and ratchetmechanism of FIG. 7 in a second rotated position;

FIG. 10 is a front elevational view of the foot bed of the hinged anklebrace of FIG. 1;

FIG. 11 is a front perspective view of another preferred embodiment ofthe present hinged ankle brace;

FIG. 12 is a rear elevational view of the hinged ankle brace of FIG. 11;

FIG. 13 is a front perspective view of an outer sleeve of the hingedankle brace of FIG. 11;

FIG. 14 is a front perspective view of another preferred embodiment ofthe present hinged ankle brace;

FIG. 15 is a front perspective view of an outer sleeve of the hingedankle brace of FIG. 14; and

FIG. 16 is a rear perspective view of an inner liner of the hinged anklebrace of FIG. 14.

DETAILED DESCRIPTION

With reference to FIGS. 1-10, one embodiment of the present hinged anklebrace 100 includes a semi-rigid shell 101. The shell 101 comprises anupper ankle cuff 102 and a lower foot bed 104. In one embodiment, thelower foot bed 104 and the upper ankle cuff 102 are each constructed ofa plastic material, such as polyamide or a composite of polyamide andABS. The material used to construct the lower foot bed 104 and the upperankle cuff 102 preferably imparts these components with semi-rigidcharacteristics, such that they generally hold their respective shapesand provide support to the wearer's ankle, but are capable of beingdeformed to match the contours of the wearer's ankle and to allow thewearer's ankle to follow its natural motion. Those of skill in the artwill appreciate that any materials having the desired properties couldbe used to construct the lower foot bed 104 and the upper ankle cuff102, and that the examples provided above are not limiting.

With reference to FIGS. 1-16, the illustrated embodiments of presentankle brace 100, 200, 300 are configured to fit a wearer's right ankle.However, those of ordinary skill in the art will appreciate that theconfiguration of the illustrated ankle braces could be reversed toprovide an ankle brace configured to fit a wearer's left ankle.Moreover, certain features and aspects of the illustrated embodimentsdiscussed further below, including the ratchetably interconnected strapsand the outer soft sleeve, could be used in conjunction with a universalankle brace, that is, one that is configured to fit either a wearer'sleft or right ankle.

As described in more detail below, in certain embodiments the hingedankle brace comprises a three-layer apparatus including an outer softsleeve 902, 1202 (FIGS. 11, 14), an inner soft liner 130, 1230 and asemi-rigid shell 101 disposed between the outer sleeve 902, 1202 and theinner liner 130, 1230. In certain embodiments, the hinged ankle brace isconfigured to be worn inside a shoe. The semi-rigid shell 101 providessufficient flexibility to conform to a wearer's anatomy, but issufficiently rigid to resist torsional distortion imparted by inversionand eversion forces. The ankle brace may be used for a variety ofpurposes including, but not limited to, prevention of ankle/footrolling, protection against high ankle sprains, and protection againstexcessive supination and/or pronation of the foot.

With reference to FIG. 2, one embodiment of the semi-rigid shell 101comprises an ankle cuff 102 and foot bed 104, wherein the ankle cuff 102and foot bed 104 are pivotally connected, such as by a hinge mechanism.Pivot points are preferably provided along both the medial and lateralsides of the foot bed 104, with the lateral pivot 106 being slightlylower than the medial pivot 108. This arrangement of the pivots 106, 108enables the pivoting action of the ankle cuff 102 with respect to thefoot bed 104 to match the natural pivoting motion of the wearer's anklein dorsi-flexion and plantar-flexion. The ankle cuff 102 and foot bed104 are preferably sufficiently flexible for conforming to the shape ofthe wearer's foot, ankle, and lower leg, while being sufficiently rigidto protect against injury. If desired, the foot bed 104 may beheat-formed or otherwise molded to conform to the wearer's foot foradditional comfort. When assembled, the semi-rigid shell 101 ispreferably open toed and open heeled.

With reference to FIGS. 2 and 7, in the illustrated embodiment, a medialstrap 140 and a lateral strap 141 extend forward from the ankle cuff102. The straps 140, 141 are preferably semi-rigid and include a ratchetmechanism to incrementally tighten the cuff and maintain the desiredtension. The lateral strap 141 preferably extends through a window 710in the medial strap 140 having a curved shape 714 for allowing thestraps 140-141 to angularly adjust. As best illustrated in FIGS. 7-9,this feature accommodates medial/lateral cuff flexing for additionalcomfort and effectiveness during use. It will further be appreciated bythose skilled in the art that the interlocking nature of the strapprovides excellent torsional rigidity and improved eversion andinversion control.

Upper Ankle Cuff

With reference to FIGS. 1 and 2, the upper ankle cuff 102 includes acalf-supporting portion 121 shaped and configured to support a posteriorside of the wearer's calf. A lateral upright 120 extends downward from alateral side of the calf-supporting portion 121, and a medial upright122 extends downward from a medial side of the calf-supporting portion121. A lower end of the lateral upright 120 is pivotally attached to acorresponding lateral wing 110 extending upward from a lateral side ofthe foot bed 104 with a lateral hinge 106. A lower end of the medialupright 122 is pivotally attached to a corresponding medial wing 112extending upward from a medial side of the foot bed 104 with a medialhinge 108. These pivotal attachments 106, 108 allow the upper ankle cuff102 and the foot bed 104 to pivot with respect to each other such thatthe ankle brace allows the ankle of a wearer to flex in dorsi-flexionand plantar-flexion. With reference to FIG. 4, in certain embodiments,the pivots 106, 108 may be arranged such that the medial pivot 108 ishigher with respect to the foot bed 104 than the lateral pivot 106.Thus, the centers of the axes of rotation for each pivot 106, 108 areoffset from one another, as illustrated in FIG. 4. Additionally, theaxes of rotation are skewed relative to a horizontal plane.Advantageously, this offset and skewed geometry of the pivots 106, 108closely resembles the anatomy of a human ankle, thus allowing the braceto closely simulate the natural bending motion of the human ankle.

In certain embodiments, the upper ankle cuff 102 may be comprised of aheat moldable material. For example, certain polyamide and polyamide/ABScomposite materials may have the desired heat moldability. In theseembodiments, advantageously, the upper ankle cuff 102 may beindividually molded to accurately conform to the particular calf anatomyof a wearer. A heat gun or other readily available heating device may beused to raise the temperature of the upper ankle cuff 102 so that itbecomes moldable, allowing each individual wearer to create a custom-fitankle cuff 102.

Semi-Rigid Straps

With continued reference to FIGS. 1 and 2, in certain embodiments theankle brace 100 includes a semi-rigid medial strap 140 and a semi-rigidlateral strap 141. The semi rigid straps 140, 141 are configured toadjustably position the ankle cuff 102 on the ankle of a wearer. In theillustrated embodiments, at least a portion of each semi-rigid strap140, 141 is formed integrally with the upper ankle cuff 102. Forexample, these portions could be molded as one piece of polyamide or acomposite of polyamide and ABS. The medial strap 140 extends forwardfrom a medial side of the upper ankle cuff 102, and the lateral strap141 extends forward from a lateral side of the upper ankle cuff 102.FIG. 1 illustrates the straps 140, 141 in an engaged position, and FIG.2 illustrates the straps in a disengaged position.

As depicted in FIGS. 7-9, the ratcheted adjustment of the medial strap140 with respect to the lateral strap 141 is provided by the engagementbetween a slot 710 disposed on the medial strap 140 and a plurality ofridges 712 disposed on the lateral strap 141. However, it is recognizedthat other ratchet mechanisms known in the art could be incorporatedinto the straps 140, 141 of the ankle brace. A curved edge 714 of theslot 710 engages one of the plurality of ridges 712, thus maintainingthe position of the two straps relative to each other. Advantageously,the ratcheted interconnection allows a wearer to repeatedly and reliablyadjust the straps to a desired size of the ankle brace. The wearer maynote the number of ridges 712 advanced through the slot 710 when theankle brace 100 is properly sized. By advancing the same number ofridges 712 through the slot 710 during each fitting, the wearer is ableto repeatedly and consistently achieve the same incremental adjustmentof the ankle brace.

With reference to FIGS. 7-9, in the illustrated embodiments theengagement side of the slot 710 includes a curved profile 714. Thiscurved profile 714 allows ratcheted interconnection of the two straps140, 141 even over a range of angles where the straps 140, 141 aretransverse to each other. FIGS. 8 and 9 illustrate the ratchetedinterconnection of the straps 140, 141 over a range of transverseorientations of the straps 140, 141 relative to each other. In FIG. 8,the straps are in a first rotated position. In FIG. 9, the straps are ina second rotated position relative to each other. The curved profile 714of the slot 710 allows the slot 710 to maintain contact with the ridges712 for all rotated positions in a range between the first rotatedposition and the second rotated position. Advantageously, this contactbetween the slot 710 and the ridges 712 allows the straps 140, 141 tosecurely conform to any of various ankle sizes and geometries.Additionally, the curved profile 714 maintains the ratchetedinterconnection between the straps 140, 141 even where a wearer'swalking or running motion rotates the straps relative to each other.

With reference to FIGS. 5-9, each of the straps 140, 141 may comprise ofa first segment 702 adjacent the ankle cuff 102 and a second segment 704spaced from the ankle cuff 102. These segments 702, 704 may comprisematerials having different rigidities. In one embodiment, the firstsegment 702 is semi-rigid, and, as noted above, is formed as a single,unitary piece with the upper ankle cuff 102. The second segment 704,however, may be relatively less rigid. Therefore, the increasedflexibility of the second segment 704 advantageously allows the straps140, 141 to closely conform to the shape of the outer surface of theankle cuff 102, thus tightly conforming the ankle brace to a wearer'sankle. The semi-rigid first segment 702 contributes to the overallsupport and stability provided to a wearer's ankle by the ankle brace100. The first segments 702 of the ratchetably interconnecting straps140, 141, combined with the calf-supporting portion 121 (FIG. 1),completely encircle the wearer's ankle. Advantageously, since the anklebrace 100 provides a semi-rigid structure completely encircling theankle of the wearer, it provides enhanced resistance to high anklesprains as compared to an ankle brace including only a soft strap.

The second segments 704 may be configured to mate with outer surfaces ofthe ankle cuff 102 through the use of fasteners such as, for example,hook-and-loop fasteners. In a preferred embodiment, as illustrated inFIG. 2, each second segment 704 includes a patch of hook fasteners 204disposed on an inner surface. An outer surface of the calf-supportingportion 121 includes a patch of loop fasteners 202 disposed thereon.When the strap 140 is in an engaged position (FIG. 1), the hookfasteners 204 and loop fasteners 202 mate to secure the straps 140, 141.Those of skill in the art will appreciate that the locations of the hookfasteners and the loop fasteners could be switched to position the loopfasteners on the straps 140, 141 and the hook fasteners on the anklecuff 102. Those of skill in the art will further appreciate that otherfasteners such as snaps, buttons, laces, zippers, or other similarfasteners could be used to adjustably secure the second segments 704 tothe ankle cuff 102.

Foot Bed

With reference to FIGS. 1-3 and 10, the foot bed 104 includes acontoured lower foot plate 150, a lateral wing 110, and a medial wing112. The wings 110, 112 extend generally upwardly from medial andlateral edges, respectively, of a posterior portion of the foot plate150. The contours of the foot plate 150 preferably follow the naturalcontours of the sole of a typical human foot. For example, the footplate 150 includes a raised portion 151 that mates with the concavity ofthe wearer's arch. The foot plate 150 underlies the entire width of thewearer's foot and extends from adjacent the ball of the wearer's foot toadjacent the wearer's heel. Therefore, the foot plate 150 provides arelatively large coverage area and sole-conforming contours that reducethe incidence of foot slippage from the foot plate 150. This largecoverage area provides various advantages over a stirrup-like footretaining section as has been previously disclosed. For example, U.S.Pat. Nos. 6,524,266 and 6,656,145 disclose stirrup-like foot retainingportions. In contrast to these stirrup-like foot retaining sections,which rely on only a narrow strip of material contacting a wearer's footfor all support of that foot, the foot plate 150 of the illustratedembodiments provides a larger contact area between the wearer's foot andthe foot plate 150. This larger contact area contributes to greatercontrol against inversion, eversion, and rotation of a wearer's foot, atleast in part by reducing the risk of foot slippage with respect to thefoot plate 150. Further, the sole-conforming contours of the foot plate150 also reduce the incidence of foot slippage from the foot plate 150,which provides further control against inversion, eversion, and rotationof the wearer's foot.

With references to FIGS. 5 and 6, which depict left and right side viewsof the semi-rigid shell 101, the lateral wing 110 includes a lateralposterior extension 114, and the medial wing 112 includes a medialposterior extension 116. Each of the posterior extensions 114, 116 isshaped substantially as a rounded lobe in side elevational view, andeach is configured to cup and support each side of the wearer's ankleand heel. The posterior extensions 114, 116 thus provide calcanealsupport to the wearer and prevent unnatural inversion and eversion.

The lateral and medial wings 110, 112 may be connected to the foot plate150 by a medial bend region 152 and a lateral bend region 154 (FIG. 10)interposed between the foot plate 150 and corresponding lateral andmedial wings 110, 112. These bend regions 152, 154 may be slightly moreflexible than the foot plate 150 to facilitate conformance of the anklebrace with the anatomy of a particular wearer. For example, the bendregions 152, 154 may be formed of the same material as the foot plate150, but be less thick than the foot plate 150. The bend regions 152,154 advantageously allow the ankle brace to fit a given individual welldespite variations in anatomical geometry across the general population.

The lateral and medial wings 110, 112 are configured to be pivotallycoupled to the lateral and medial uprights 120, 122 of the upper anklecuff 102. With reference to FIG. 2, a medial hinge 108 pivotally couplesthe medial wing 112 of the foot bed 104 with the medial upright 122 ofthe ankle cuff 102 and a lateral hinge 106 pivotally couples the lateralwing 110 of the foot bed 104 with the lateral upright 120 of the anklecuff 102. As discussed above, in certain embodiments, the medial pivot108 is higher with respect to the foot plate 150 than the lateral pivot106. Advantageously, this geometry closely resembles the anatomy of ahuman ankle, thus allowing the ankle brace to closely simulate anankle's natural bending motion. As depicted, the lateral and medialhinges 106, 108 comprise rotatable riveted connections. However, thoseof skill in the art will appreciate that other rotatable connectionscould be used instead.

With reference to FIGS. 1-3, a substantially semi-circular cut-outportion 160 of the foot plate 150 receives the wearer's heel. Asexplained above, in certain embodiments, the ankle brace 100 may be wornwithin a shoe of a wearer. The cut-out portion 160 enables the wearer'sheel to engage the insole of the wearer's shoe, such that the foot plate150 does not interfere with the cushioning provided by the shoeLikewise, in the illustrated embodiments the foot bed 104 does notextend under the ball of the wearer's foot, thus allowing the shoe tocushion standing, walking, and running loads on the heel and the ball ofthe wearer's foot.

In certain embodiments, the foot bed 104 may be comprised of a heatmoldable material. For example, certain polyamide and polyamide/ABScomposite materials may have the desired heat moldability. In theseembodiments, advantageously, the foot bed 104 may be individually moldedto accurately conform to the particular foot anatomy of a wearer or aparticular shoe or orthotic to be worn by the wearer. A heat gun orother readily available heating device may be used to raise thetemperature of the foot bed 104 so that it becomes moldable, allowingeach individual wearer to create a custom-fit foot bed 104.

In certain embodiments, the foot bed 104 may be comprised of a trimmablematerial. For example, certain polyamide and polyamide/ABS compositematerials may be trimmable. In these embodiments, advantageously,material may be trimmed from the foot bed 104 to accurately conform thefoot bed 104 to the foot anatomy of a particular wearer or to a shoe ofthe wearer. Scissors, knives, saws, rotary tools, or other cuttingdevices may be used to trim the foot bed 104.

Inner Liner

In certain embodiments, the present ankle brace includes an inner liner.As depicted in FIGS. 1, 3 and 11-12, the inner liner 130 is sized andshaped to underlie the ankle cuff 102. With reference to FIG. 3, theinner liner 130 has a calf-supporting portion 131 configured to encirclethe wearer's lower calf, a medial upright 133 extending downward from amedial side of the calf-supporting portion, and a lateral upright 135extending downward from the lateral side of the calf-supporting portion.FIG. 3 illustrates a partially exploded view of the ankle brace 100 withits inner liner 130 removed from its semi-rigid shell 101. The innerliner 130 may be comprised of a soft, compressible material. In oneembodiment, the inner liner 130 is comprised of an EVA foam innercushion in a brushed polyamide outer layer. Alternatively, the innerliner 130 could be comprised of polyurethane foam, polyethylene foam,microspheres (such as glass) contained in a lubricant matrix (such asmineral oil), other gels and foams, or pneumatics. Advantageously, theinner liner 130 provides a comfortable fit for the wearer as well asstability.

The inner liner 130 may include at least one generally vertical channel301. The channel 301 is formed on an inner surface of the inner liner130. The channel may extend below the surface of the inner liner 130.The channel 301 allows the inner liner 130 to flex. This flexibilityenhances the ability of the inner liner 130 to encircle and maintaincontact with ankles having a variety of sizes and shapes.

The inner liner 130 is preferably removable from the ankle cuff 102.FIG. 1 illustrates the ankle brace 100 with an inner liner 130 insertedin the ankle cuff 102. FIGS. 2-6 illustrate a semi-rigid shell 101 ofthe ankle brace 100 with the inner liner 130 removed. Preferably, thisremovability may be achieved with hook-and-loop fasteners. In certainembodiments, a portion of a brushed polyamide surface of the inner liner130 serves as the loop component of a hook-and-loop fastener. At leastone patch of hooks 302 (FIGS. 2, 3) may be adhered to an inner surfaceof the ankle cuff 102 such that the inner liner 130 may be removablyattached thereto. Alternatively, other fasteners known in the art suchas snaps, zippers, buttons, or adhesive strips may be used to removablyor permanently attach the inner liner 130 to the ankle cuff 102.Advantageously, a removable inner liner 130 may be removed for variousreasons including to be cleaned, dried, laundered, or replaced with aninner liner 130 of a different size.

With reference to FIG. 3, the calf-supporting portion 131 of the innerliner 130 is shaped and configured to provide support for the posteriorof the wearer's ankle and is open at an anterior side to allow thewearer to easily don the inner liner 130. The inner liner 130 may alsocomprise an adjustable fastener such that the inner liner 130 may beadjustably conformed to a wearer's ankle. Preferably, this adjustablefastener comprises a hook-and-loop fastener. The outer surface of theinner liner may serve as a loop portion of a hook-and-loop fastener,configured to mate with a patch of hooks 304 on an inner surface of theinner liner 130. Other fasteners such as laces, snaps, buttons, zippersor other similar adjustable fasteners may be used to adjust the innerliner 130.

FIGS. 14-16 illustrate another embodiment of the present ankle brace 300in which an inner liner 1230 additionally includes an Achilles heel pad1234 to provide enhanced comfort and stability to a wearer's ankle. FIG.16 illustrates the inner liner 1230 to be used with the ankle brace 300in the embodiment illustrated in FIG. 14. The inner liner 1230 includesa calf-supporting portion 1221 sized and configured to encircle thewearer's lower calf, a lateral upright 1220 extending downward from alateral side of the calf-supporting portion, a medial upright 1222extending downward from a medial side of the calf-supporting portion,and an Achilles heel pad 1234 extending downward from a posterior sideof the calf-supporting portion 1221. The medial and lateral uprights1220, 1222 extend anteriorly such that they overlap at an anterior faceof the inner liner 1230. The Achilles heel pad 1234 provides additionalcomfort and support to the wearer's heel. Additionally, the Achillesheel pad provides cushioning to the wearer's heel when the inner liner1230 is worn in conjunction with a compressive outer sleeve 1202 asdepicted in FIG. 15 and discussed further below. Preferably, theAchilles heel pad 1234 has at least one vent 1232 therein to promotebreathability of the ankle brace.

Outer Sleeve

FIGS. 11 and 12 illustrate another embodiment of the present ankle brace200, which comprises a removable outer sleeve 902. The outer sleeve 902is an adjustable soft band that is sized and configured to encircle thesemi-rigid shell 101 at a location overlying the wearer's ankle joint.In the illustrated embodiments, the outer sleeve 902 is a generallyrectangular band whose ends may be overlapped to form a generallycylindrical segment whose inner diameter can be varied by adjusting theamount of overlap of the ends.

The outer sleeve is best illustrated in FIG. 13. The outer sleeve 902may be comprised of a relatively inelastic fabric that is strong anddurable such as a polyester material. The outer sleeve 902 is configuredto be positioned outside the ankle cuff 102 at a location approximatelyoverlying the ankle joint of a wearer. The outer sleeve 902 thusprovides ankle joint compression to a wearer by compressing thesemi-rigid ankle cuff 102 and foot bed 104 around the ankle of a wearer.This ankle joint compression provides additional support to the wearer'sankle joint.

The circumference of the outer sleeve 902 is preferably securablyadjustable. As depicted this securable adjustability is provided by aplurality of laces 904 passing through a tongue lace guide 906 andopposing eyelets 908 on the outer sleeve 902. Ends of the laces 904 aresecurable to the outer sleeve 902 with hook-and-loop fasteners 910. Inthe illustrated embodiments, the outer surface of the outer sleeve 902forms the loop portion of the fastener, and the hook portion is providedby a patch to which the ends of the laces are affixed. Advantageously,this combination of laces 904 with hook-and-loop fasteners 910facilitates rapid application, adjustment, and removal of the outersleeve 902. But, it is recognized that other fastening devices such asknotted laces, flexible hook-and-loop straps, elastic bands, and othersimilar securable adjustable devices may be used in conjunction with anouter sleeve 902 to provide the desired ankle joint compression.

In other embodiments, as depicted in FIGS. 14-16, an ankle brace 300 mayfurther comprise a removable outer sleeve 1202 that provides enhancedsupport. The outer sleeve 1202 is configured to overlie the foot bed 104and a lower portion of the ankle cuff 102. The outer sleeve 1202 thusprovides enhanced support to a wearer by compressing the foot bed 104around the wearer's foot and by compressing ankle cuff 102 around thewearer's ankle joint. The outer sleeve 1202 is preferably adjustablysecurable. A plurality of laces 1204 interwoven through a tongue laceguide 1206 and opposing eyelets 1208 on the outer sleeve 1202 mayprovide this adjustable securability. Ends of the laces 1204 may beadjustably secured to the outer sleeve 1202 with hook-and-loop fastenerssubstantially as described above with respect to the embodiments ofFIGS. 11-13. Also, other suitable fasteners such as knotted laces,flexible hook-and-loop straps, elastic bands, or other similar securableadjustable devices may be used in conjunction with an outer sleeveproviding enhanced support.

Applying the Present Ankle Brace

A wearer may don the ankle brace illustrated in FIGS. 1-10 with the semirigid shell 101 and the inner liner 130 in an open configuration asillustrated in FIG. 3. The wearer applies the inner liner 130 to his orher lower calf such that the calf-supporting portion 131 covers aposterior side of the wearer's ankle and the lateral and medial uprights135, 133 extend down corresponding lateral and medial sides of thewearer's ankle. The wearer may then secure the inner liner 130 aroundthe ankle by applying the patch of hooks 304 to a loop portion formed ona surface of the inner liner 130. The wearer also securably positionsthe inner liner 130 in the semi-rigid shell 101 such that the innerliner 130 is substantially aligned with the ankle cuff 102. Patches ofhooks 302 may mate with an outer surface of the inner liner 130 tosecure the inner liner 130 with respect to the semi-rigid shell 101. Theinner liner 130 may be securely positioned in the semi rigid shell 101before the wearer applies the inner liner to the ankle. Alternatively,the inner liner 130 and semi-rigid shell 101 may be applied in sequence.As the wearer applies the inner liner 130 and securely positions theinner liner 130 in the semi-rigid shell 101, the wearer's foot shouldalign with the foot bed 104 such that the wearer's heel is in thecut-out portion 160 of the foot bed 104, the sole of the wearer's footis resting on the foot bed 104, and the ball of the wearer's foot isadjacent the foot bed 104.

The wearer then interconnects the straps 140, 141 by passing an end ofthe lateral strap 141 through the slot 710 of the medial strap 140. Asdiscussed above, the wearer may incrementally adjust the straps 140, 141by advancing a desired number of ridges 712 on the lateral strap 141through the slot 710. Once a desired adjustment has been achieved, thewearer secures ends of the straps 140, 141 to the ankle cuff 102. Thissecuring may be accomplished by fastening hook fasteners 204 on thesecond segments 704 of the straps 140, 141 to loop portions 202 on asurface of the ankle cuff 102.

To don other embodiments of ankle brace as illustrated in FIGS. 11-15,the wearer may also apply an outer sleeve 902 (FIGS. 11-13), 1202 (FIGS.14-15). In certain instances, the outer sleeve 902, 1202 may have beenpreviously applied to the semi-rigid shell 101 such that to apply theouter sleeve 902, 1202 the wearer inserts a foot through the outersleeve 902, 1202 and advances the foot and ankle until the ankle brace200, 300 is appropriately positioned around the wearer's foot and ankleas discussed above. The wearer would then securably adjust the outersleeve 902, 1202, by tightening laces on the outer sleeve 902, 1202 andsecuring the ends of the laces by, for example, using a hook and loopfastener. Alternatively, the wearer may apply the outer sleeve 902,1202, after the semi-rigid shell 101 has been applied. The wearer wouldslidably advance the outer sleeve 902, 1202 over the foot in the footbed 104 of the semi-rigid shell 101, into the appropriate position. Inapplying a band type outer sleeve of the embodiments illustrated inFIGS. 11-13, the outer sleeve 902 would be advanced until it overliesthe wearer's ankle. In applying an outer sleeve with enhanced support,as illustrated in FIGS. 14-15, the outer sleeve 1202 would be advanceduntil it substantially covers a lower surface of the foot plate 104.Once advanced, the outer sleeve 902, 1202 would be securely adjustedusing an adjustable fastener at the end of the laces.

SCOPE

The above presents a description of the best mode contemplated forcarrying out the present ankle brace, and of the manner and process ofmaking and using it, in such full, clear, concise, and exact terms as toenable any person skilled in the art to which it pertains to make anduse this ankle brace. This ankle brace is, however, susceptible tomodifications and alternate constructions from that discussed above thatare fully equivalent. Consequently, this ankle brace is not limited tothe particular embodiments disclosed. On the contrary, this ankle bracecovers all modifications and alternate constructions coming within thespirit and scope of the ankle brace as generally expressed by thefollowing claims, which particularly point out and distinctly claim thesubject matter of the ankle brace.

What is claimed is:
 1. An ankle brace comprising: a semi-rigid anklecuff including: a calf-supporting portion configured to extend around alower calf of a wearer; a medial upright extending generally downwardfrom a medial side of the calf-supporting portion; and a lateral uprightextending generally downward from a lateral side of the calf supportingportion; and a semi-rigid foot bed coupled to the semi-rigid ankle cuff,the semi-rigid foot bed including: a foot plate comprising a posteriormedial edge and a posterior lateral edge, the foot plate contoured tounderlie at least a portion of a foot of the wearer; a medial wingextending generally upward from the posterior medial edge of the footplate; a lateral wing extending generally upward from a posteriorlateral edge of the foot plate; a medial bend region joining the medialwing to the foot plate; and a lateral bend region joining the lateralwing to the foot plate, wherein each of the medial bend region and thelateral bend region are more flexible than the foot plate.
 2. The anklebrace of claim 1, wherein the medial wing and the lateral wing eachfurther comprise posterior extensions configured to provide calcanealsupport to the wearer.
 3. The ankle brace of claim 1, wherein theposterior extensions have a substantially rounded lobe shape configuredto support a heel and an ankle of the wearer.
 4. The ankle brace ofclaim 1, wherein the semi-rigid ankle cuff is moldable to custom fit thewearer of the ankle brace.
 5. The ankle brace of claim 1, wherein thesemi-rigid ankle cuff comprises a heat-moldable material.
 6. The anklebrace of claim 1, further comprising: a medial hinge pivotally couplingthe medial wing of the semi-rigid foot bed and the medial upright of thesemi-rigid ankle cuff; a lateral hinge pivotally coupling the lateralwing of the semi-rigid foot bed and the lateral upright of thesemi-rigid ankle cuff, wherein the medial hinge is disposed higher, withrespect to the foot plate, than the lateral hinge.
 7. The ankle brace ofclaim 6, wherein at least one of the medial hinge and the lateral hingecomprises a rotatable riveted connection.
 8. The ankle brace of claim 1,wherein the semi-rigid foot bed is rotatably coupled to the semi-rigidankle cuff.
 9. The ankle brace of claim 1, wherein the semi-rigid footbed is configured to fit within a shoe of the wearer.
 10. The anklebrace of claim 1, wherein the semi-rigid foot bed further comprises acut-out portion configured to receive a heel of the wearer.
 11. Theankle brace of claim 1, wherein the foot plate is configured to underliethe foot of the wearer over an area spanning a width of the wearer'sfoot and configured to extend from adjacent a ball of the wearer's footto adjacent a heel of the wearer.
 12. The ankle brace of claim 1,wherein the foot plate comprises a raised portion configured to matewith a concavity of an arch of the foot of the wearer.
 13. The anklebrace of claim 1, further comprising a liner removably attached to thesemi-rigid ankle cuff.
 14. The ankle brace of claim 13, wherein theliner comprises an Achilles pad configured to cover an Achilles heel ofthe wearer.
 15. The ankle brace of claim 1, further comprising an outersleeve configured to be disposed over an ankle joint of the wearer. 16.The ankle brace of claim 15, wherein the outer sleeve is furtherconfigured to surround a forward edge of the semi-rigid foot bed. 17.The ankle brace of claim 1, further comprising at least one semi-rigidstrap extending from the calf-supporting portion and including a ratchetmechanism to adjustably position the semi-rigid ankle cuff.
 18. Theankle brace of claim 17, wherein at least a part of the at least onesemi-rigid strap is formed integrally with the calf-supporting portion.19. The ankle brace of claim 17, wherein the at least one semi-rigidstrap comprises: a medial strap extending forward from the medial sideof the calf-supporting portion; and a lateral strap extending forwardfrom the lateral side of the calf-supporting portion, wherein the medialstrap and the lateral strap are configured to mate such that acircumference of the semi-rigid ankle cuff is incrementally adjustable.20. The ankle brace of claim 17, wherein the ratchet mechanism providesincremental adjustability.